Conductive Line Junction Preventing Bulging in Hybrid Vehicles
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Solution Overview
Problem
The connection of single-core and stranded electrical lines in conductive lines for hybrid or electric vehicles poses challenges due to bulging junctions, which interfere with heat shrink tubes and shield pipes, making it difficult to achieve a reduced diameter for the shield pipe and optimal installation space.
Innovation Solution
A conductive line configuration where a single-core line is connected to a stranded line with stripped sheathings, and the conductor and individual wires are welded to form a coaxial connection, ensuring the junction portion is aligned and protected by a heat shrink tube, preventing bulging and facilitating easier insertion into shield pipes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If single-core line electrical lines are used in the shield pipe portion, then the diameter of the shield pipe can be reduced, but the flexibility and ease of bending required for routing outside the shield pipe cannot be met
Solution Approach 1:
The conductive line is divided into two distinct portions: a single-core line portion (inside the shield pipe) and a stranded line portion (outside the shield pipe). This segmentation allows each portion to be optimized for its specific function - the single-core line minimizes diameter for shield pipe installation, while the stranded line provides flexibility for routing outside the shield pipe.
2Ease of operation
If stranded electrical lines are used outside the shield pipe, then flexibility is improved, but the diameter of the shield pipe cannot be reduced
Solution Approach 1:
The conductive line is divided into two distinct portions: a single-core line portion (inside the shield pipe) and a stranded line portion (outside the shield pipe). This segmentation allows each portion to be optimized for its specific function - the single-core line minimizes diameter for shield pipe installation, while the stranded line provides flexibility for routing outside the shield pipe.
3Volume of moving object
If single-core line is connected to stranded electrical line, then both flexibility and reduced diameter are achieved, but the junction portion bulges in the diameter direction causing interference with heat shrink tube and shield pipe
Solution Approach 1:
The sheathings of both the single-core line and stranded line are stripped in advance before connection, exposing the conductors. This preliminary action allows for precise alignment and coaxial connection, preventing the junction portion from bulging in the diameter direction and interfering with the heat shrink tube and shield pipe.
Solution Approach 2:
The connection is designed to maintain coaxial alignment in the diameter direction, effectively using the longitudinal dimension for connection while preventing dimensional expansion in the radial dimension. This ensures the junction portion does not bulge outward.
4Reliability
If sheathings are stripped and conductors are welded to form a block, then connection reliability is improved, but the junction portion protrudes more outward in the diameter direction
Solution Approach 1:
The sheathings of both the single-core line and stranded line are stripped in advance before connection, exposing the conductors. This preliminary action allows for precise alignment and coaxial connection, preventing the junction portion from bulging in the diameter direction and interfering with the heat shrink tube and shield pipe.
Solution Approach 2:
The connection is designed to maintain coaxial alignment in the diameter direction, effectively using the longitudinal dimension for connection while preventing dimensional expansion in the radial dimension. This ensures the junction portion does not bulge outward.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration allows for the use of single-core lines with reduced diameters, optimizing space and weight, while avoiding interference with heat shrink tubes and shield pipes, ensuring reliable connections and reduced installation complexity.
Implementation Method 1
the conductor and individual wires are welded to form a block
Data Source
AI summary
A connection portion between a single-core line electrical line and a stranded electrical line is prevented from bulging in the diameter direction. A conductor exposed portion is formed on an end portion of the single-core line electrical line, and an individual wire exposed portion is formed on an end portion of the stranded electrical line. A collapsed portion is formed on the conductor exposed portion, and a connection block portion is formed by welding together individual wires of the individual wire exposed portion. The compressed portion and the connection block portion are joined in an overlapping state. At this time, the collapsed portion is bent such that a level difference is formed in the diameter direction such that the single-core line electrical line and the stranded electrical line are joined approximately coaxially.